Interface for industrial controller network card

ABSTRACT

An interface between a network communication card and an industrial controller allows rapid asynchronous buffering using two buffers and two associated registers for each data direction. A reading of the buffers is proceeded by an attempt to copy from the write designation register to the read designation register checking the equality of the register values and then reading from the buffer designated by their common value. Conclusion of the reading sets the write destination register to zero. Writing of the buffers is proceeded by a checking of the read designation register for zero value and then writing to other than the last buffer indicated by the write designation register. If the read designation register is non-zero, then the writing occurs to the opposite buffer of that in the read designation register. The write designation register is then updated to indicate the buffer written to.

CROSS-REFERENCE TO RELATED APPLICATIONS Statement Regarding Federally Sponsored Research or Development BACKGROUND OF THE INVENTION

The present invention relates to industrial controllers and in particular to a network card that may be attached to industrial controllers to allow the industrial controller to communicate to communication networks of different protocols.

Industrial controllers are special purpose computers used for controlling industrial processes and manufacturing equipment. Under the direction of a stored control program, the industrial controller examines a series of inputs reflecting the status of a controlled process and in response, adjusts a series of outputs controlling the process. The inputs and outputs may be binary, that is, on or off, or analog providing a value within a continuous range of values.

Industrial controllers may communicate with other industrial controllers or remote input and output (I/O) devices by means of well known high speed serial communication networks such as Ethernet, ProfiBus, FieldBus, FireWire, and DeviceNet or by proprietary data networks such as the Data Highway series protocols developed by the assignee of the present application. In order to accommodate this variety of different communication protocols, the industrial controller may be constructed in modular form to allow different network cards to be attached to the industrial controller to communicate with the industrial controller through a common communication interface. Each communication card may be tailored to provide communications with a different network to which it also attaches.

The interface between the network card and the industrial controller must efficiently transmit large amounts of data between the network card (and thus the network) and the industrial controller as part of the communication process. This data exchange may be asynchronous meaning that the reading and writing of data by the network card and the industrial controller may not synchronized with each other.

One simple method of accommodating the transfer of large amounts of asynchronous data between the industrial controller and the network card is by the use of a dual port memory into and from which the industrial controller and the network card may independently write and read. Unfortunately the asynchronicity in reading and writing may allow a portion of the dual port memory to be read at the same time as it is being written thus producing erroneous data. While prohibiting simultaneous reading and writing of the memory may solve this problem, this defeats the purpose of a dual port memory in allowing rapid data transfer.

BRIEF SUMMARY OF THE INVENTION

The present invention provides an extremely simple protocol that allows a dual port memory to be used as an interface between an industrial controller and a network card with simultaneous reading and writing of that dual port memory. Generally, the memory is divided into at least two buffer areas and two registers are used to indicate generally the target of writing (the “valid buffer register”) and the target of reading (the “consumer access register”), respectively. The reading device copies the contents of the valid buffer register to the consumer access register until the two are the same, then reads from the buffer indicated by the consumer access register clearing it when it is done. The writing device reads the consumer access register. If it is clear, it writes to the opposite buffer indicated by the valid buffer register. If it is not clear but indicates one of the two buffers, it copies the contents of the consumer access register to the valid buffer register, then it writes to the other buffer than that indicated. In either case, the value of the buffer written to is put into the valid buffer register. Read and write conflicts are thereby precluded.

Specifically, then, the present invention provides an interface for a network card that may be replaceably attached to an industrial controller to provide transmission on a communication network of messages sent from the industrial controller and receipt from the communications network of messages sent to the industrial controller. The interface includes a first and second buffer. A valid buffer register holds a value indicating one of the first and second buffers. A consumer access register holds a value indicating the first or second buffer or when cleared, neither of the first or second buffers. An electronic computer executes a stored program prior to reading one of the first and second buffers to copy a value from the valid buffer register to the consumer access register and then to confirm that the value of the consumer access register equals the value of the valid buffer register. The computer then reads a buffer indicated by the consumer access register and upon completion of the reading clears the consumer access register.

Thus it is one object of the invention to provide an extremely simple protocol that ensures that buffers are not simultaneously written to and read. By copying the valid buffer register to the consumer access register, the reading device provides a signal to any writing devices that a reading is occurring.

It is another object of the invention to prevent errors called by asynchronous reading and writing where the writing device completes a write during the step of copying from the valid buffer register to the consumer access register. The confirming of the value of the consumer access register to be equal to the value of the valid buffer register prevents a writing device from reacting to a stale value in the consumer access register in between the time it takes to read the valid buffer register and write it to the consumer access register.

It is yet another object of the invention to allow a signaling to the writing device of the completion of the reading that is distinct from an indication of one of the two buffers. The clearing of the consumer access register provides this indication

If the value of the consumer access register cannot be confirmed to be equal to the valid buffer register, the electronic computer may repeat the copying process.

Thus it is another object of the invention to allow reading of a buffer to commence as soon as possible after an intervening write of the buffer has been completed such as may change the valid buffer register.

The valid buffer register and the consumer access register in the first and second buffers may be designated portions of a continuous memory space in electronic memory.

Thus it is another object of the invention to allow the present interface to work with a general dual port memory device.

Prior to writing to one of the first and second buffers, the electronic computer may read the consumer access register and when the consumer access register indicates one of the first and second buffers, the electronic computer may write to a buffer that is not indicated by the consumer access register and write the value of the written buffer in the valid buffer register upon completion of the writing. On the other hand, if the consumer access register indicates neither of the first and second buffers, the electronic computer may read the valid buffer register and write to a buffer that is not indicated by the valid buffer register and write a value of the written buffer into the valid buffer register upon completion of the writing.

Thus it is another object of the invention to provide for an efficient method of locking out a writing device when a reading of the buffer is occurring that minimizes the necessary reading of the registers. If a reading process is ongoing, a single read of the consumer access buffer allows the writing device to determine where the proper target buffer is.

It is another object of the invention to provide the writing device the maximum flexibility in selecting the buffer to write if no reading of either buffer is occurring.

The foregoing and other objects and advantages of the invention will appear from the following description. In the description, reference is made to the accompanying drawings which form a part hereof, and in which there is shown by way of illustration a preferred embodiment of the invention. Such embodiment does not necessary represent the full scope of the invention, however, and reference must be made to the claims herein for interpreting the scope of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a simplified perspective view of an industrial controller incorporating a replaceable network card of the present invention and showing a network connection thereto;

FIG. 2 is a schematic block diagram of the industrial controller and the network card as connected through a releasable connector showing a shared dual port memory and interface lines between processors of the host and card;

FIG. 3 is a detailed version of FIG. 2 showing partitioning of the half of the dual port memory into two buffers and a consumer access register and a valid buffer register for one producer-consumer pair;

FIG. 4 is a flow chart showing operation of the consumer of FIG. 3 preparing to read one of the buffers;

FIG. 5 is a flow chart similar to FIG. 4 showing operation of the consumer of FIG. 3 preparing to write to one of the buffers;

FIGS. 6a and 6 b are flow charts juxtaposed to show relative times between operation of the host in FIG. 6a in negotiating for new partitioning values of the buffers and operation of the network card FIG. 6b in responding to such proposals for new buffering space.

DETAILED DESCRIPTION OF THE INVENTION

Referring now to FIG. 1, an industrial control system 10 may include a controller 12 incorporating an internal microprocessor and memory (not shown in FIG. 1) and one or more input/output (I/O) ports 14 communicating with a controlled process or the like. A network 16 may connect to the industrial controller 12 via a removable network card 18. One end of the network card 18 holds a network connector 20 connecting to the network 16 and on the other end of the network card 18 holds a first interface connector 22 received by a corresponding second interface connector 24 on the controller 12. The first and second interface connectors 22 and 24 permit different network cards 18 (not shown) to be attached to the controller 12 so that it may be used with different types of networks. The controller 12 may support multiple network cards 18 allowing it to communicate with several networks 16 and to operate as a bridge.

Referring to FIG. 2, the interface connectors 22 and 24, when joined, allow communication between a processor 26 of the controller 12 and a dual port memory 28 within the network card 18. By using a dual port memory 28 as a medium of communication between the controller 12 and the network card 18, a standard Personal Computer Memory Card (PCMCIA) electrical interface may be adopted, such as is known in the art. In keeping with this standard, the connectors 22 and 24 also allow for the transmission of power, ground and various control signals between the controller 12 and the network card 18.

A second processor 30 in the network card 18 also communicate via interrupt lines 34 through interface connectors 22 and 24 with the processor 26 of the controller 12 and communicates with a second port of the dual port memory 28. The dual port memory 28 allows the processors 26 and 30 to exchange data with the dual port memory asynchronously meaning that they may independently read and write from and to the dual port memory 28 at arbitrary times. The interrupt lines 34 allow processor 30 to interrupt processor 26 and allow processor 26 to interrupt processor 30. As is understood in the art, an interrupt line, when raised, causes a processor to suspend its execution of a current program and to jump to a predefined interrupt routine and to complete the execution of that interrupt routine before returning to its previous program. The use of interrupts avoids the need for a processor or other device to poll a particular input or output value or memory location such as may be unduly time consuming if rapid response is required

Processor 26 of the controller 12 communicates also via an internal bus 32 with a separate memory 29 and with the I/O port 14. The memory 29 holds a control program for the controlled process, an operating system, and programming to execute the present invention as will be described.

Similarly, processor 30 of the network card 18 may also communicate via a bus 37 with a communication circuit 39 providing for lower level protocols necessary to communicate on network 16. These low level protocols include but are not limited to the above mentioned high speed serial communication networks of Ethernet, ProfiBus, FieldBus, FireWire, and DeviceNet or by proprietary data networks such as the Data Highway series protocols developed by the assignee of the present application, all well known in the art or commercially available. Processor 30 of the network card 18 may also communicate via bus 37 with a nonvolatile memory 41 holding default buffer partitioning values as will be described and an operating program and programming to execute the present invention as will be described.

Referring to FIG. 3, in order to provide for reliable exchange of data between the controller 12 and the network card 18, the dual port memory 28 may be partitioned to provide for two buffer and two control registers for each direction of data flow between the controller 12 and the network card 18. In this regard, the controller 12 may act as either a data producer 52 when it is writing to the dual port memory 28 or data consumer 50 when it is reading from the dual port memory 28. Likewise the network card 18 may act as a data producer 52 when it is writing to the dual port memory 28 or data consumer 50 when it is reading from the dual port memory 28. One producer 52 and one consumer 50 define a direction of data flow.

The protocols for data producer 52 and data consumer 50 do not change depending on whether the data producer 52 and data consumer 50 are the controller 12 or network card 18. Accordingly, the example of a single data producer 52 and data consumer 50 may be provided.

For each data direction, the dual port memory 28 provides a first buffer 36 and a second buffer 38 communicating via address and data bus 40 a with the data consumer 50 and with address and data bus 40 b with the data producer 52. Generally these address and data buses 40 a and 40 b also serve the opposite data direction as well as reflecting the fact that the controller 12 and network card 18 may only read or write at one time.

Also for each data direction, a consumer access register 42 and a valid buffer register 44 are provided by a dual port memory 28 accessible by the address and data buses 40 a and 40 b, respectively. For practical reasons, each of the consumer access register 42 and the valid buffer register 44 are eight bits, however, it will be understood that smaller register sizes may be sufficient. The consumer access register 42 must hold three values, nominally 0, 1 and 2, indicating respectively that no buffer, the first buffer 36 or the second buffer 38 are being read. The valid buffer register 44 must hold at least two values, nominally 1 and 2, indicating, respectively, that the first buffer 36 or the second buffer 38 has last been written to. Page: 8 The valid buffer register may hold additional values such as those indicating that the producer hasn't written yet; and that the buffer is no longer valid or the data has not been updated which are not required in the present invention.

Generally, during the transfer of data from the data producer 52 to the data consumer 50, data must be buffered in one of buffers 36 and 38. Critical to efficient buffering, given the asynchronicity provided by the dual port memory 28, is preventing a reading of one buffer while writing of that buffer is ongoing such as may result in data errors. The valid buffer register 44 and the consumer access register 42, and the protocol of the present invention assure that no concurrent reading and writing of the same buffer occurs.

Referring then to FIG. 4, a data consumer 50 wishing to Had from buffer 36 or 38 begins as indicated by process block 46 by copying the value from the valid buffer register 44 to the consumer access register 42. This step is intended to provide information to the producer 52 as to a state of current reading by the consumer 50.

The transfer of data between the valid buffer register 44 and the consumer access register 42, according to normal computer protocol, requires a reading of the valid buffer register 44 in a first operation and a writing to the consumer access register 42 in a second operation. In between this reading and writing, as will be understood from the description provided below, the producer 52 as a result of its asynchronous operation, could conceivably change the valid buffer register 44 and begin a new write operation using an invalid value of the consumer access register 42, as will be described below. Accordingly at decision block 48, the consumer 50 reads the valid buffer register 44 and consumer access register 42 to check to see if they are the same.

If at decision block 48, the values are not the same, then the consumer 50 repeats process block 46 recognizing the probability of an intervening writing operation. The duration of the writing operation makes it unlikely that multiple repeats of this loop will occur, but the possibility is accommodated by the protocol, which will continue to loop as required.

When at decision block 48, if the values of the valid buffer register 44 and the consumer access register 42 are the same, then the consumer 50 proceeds to process block 54 and the buffer indicated in the consumer access register 42 is read. Subsequent changes of the valid buffer register 44 by the producer 52 are acceptable because the value of the consumer access register 42 has been set properly.

At the conclusion of the reading of the buffer by the data consumer 50, and as indicated at process block 56, a zero is written to the consumer access register 42 clearing it. It will be recognized that the particular designation of the cleared state and in fact of the buffers 36 and 38 are arbitrary so long as three distinct states are used and both the consumer and producer are using the same three distinct states. This concludes the reading process by either the controller 12 or the network card 18.

Referring now to FIG. 5, when the producer 52 wishes to write to one of the buffers, it begins as indicated by process block 60, by reading the consumer access register 42 to see whether the data consumer 50 is currently reading a buffer 36 or 38. At decision block 62, if the consumer access register 42 is cleared indicating there is no on-going reading either buffer 36 or 38, then the data producer 52 proceeds to process block 64 and writes to the buffer 36 or 38 that is not indicated in the valid buffer. Thus, for example, if the valid buffer register 44 indicates buffer 36, the producer writes to buffer 38. In this way, the producer 52 has maximum flexibility to avoid rewriting the latest written buffer 36 or 38.

Referring again to decision block 62, if the consumer access register 42 is not clear indicating that a reading of one of the buffers 36 and 38 is ongoing, then at process block 67, the producer 52 writes the consumer access register back to valid buffer register and then writes to the buffer not indicated by the consumer access register 42. Thus, for example, if the consumer access register 42 indicates buffer 36, the producer writes to buffer 38. In any case, as indicated by process block 68 following process block 64 and 67, at the conclusion of the writing of the buffer, the designator of the written buffer is stored in the valid buffer register 44 thus to serve as an indication to the consumer 50 as the next buffer to read as has been described above.

Referring now to FIGS. 2, 3 and 6 a and 6 b, the present invention allows the size of the common areas 66 and their partitioning to be varied depending upon the particular controller 12 and the expected size of data being transferred. For example, when the common areas 66 are used to communicate I/O values, it may be desirable to vary the size of the common area 66 used for this purpose according to the number and type of I/O used in the controlled process. Nevertheless, the present invention also recognizes that it is desirable that the network card 18 be immediately available with default buffer sizes when optimized buffer sizes are not critical.

In the preferred embodiment, multiple negotiable buffer areas may be provided each having an associated size variable as indicated in Table I as follows:

TABLE I Buffer Size Variable Length Host to Card Message Queue Size 4 Bytes Host to Card Message Area Size 4 Bytes Card to Host Message Queue Size 4 Bytes Card to Host Message Area Size 4 Bytes Input Image Table Size 4 Bytes Output Image Table Size 4 Bytes Card to Host Mailbox Queue Size 4 Bytes Connected Data Mailbox Size 4 Bytes Host Scratch Area Size 4 Bytes

Generally the queues provide a control function indicating the type and location of data stored in their corresponding message or mailbox areas. The image tables store values of I/O used in the control process as communicated over the I/O ports (see FIG. 1). The network card 18 may act as a scanner collecting I/O data from remote devices attached to the network 16 and placing it in the image tables. The scratch area allows the network card 18 to act as added memory for the controller 12.

Referring to FIGS. 6a and 6 b, when powered-up, network card 18 at process block 70 writes default values for each of the size variables of Table I from its nonvolatile memory 41 to a common area 66 in the dual port memory 28 where the size variables are stored. The network card 18 then interrupts the controller 12 via the interrupt lines 34.

As indicated by process block 74, upon receiving the interrupt, the controller 12 may read the default values in the common area 66. If these values are acceptable to the controller 12 as indicated by decision block 75, then no further action is taken. However, if the controller 12 has preferred sizes for one or more of these buffer areas, then at process block 76, it may overwrite the default values stored in the common area 66. At this time, an interrupt is generated as indicated by interrupt symbol 78.

In response to the interrupt, the network card 18 reads the overwritten values at process block 80 and checks them against its internal operating limits such as may be programmed into nonvolatile memory 41. These limits may include the size of the dual port memory 28, predetermined minimums for certain messaging functions and compatibility between designated queue and messaging or mailbox areas.

If the values proposed by the controller 12 are acceptable to the network card 18, as determined by decision block 82, the program of the network card 18 proceeds to process block 84 where a response is made to the controller 12 indicating such via a special negotiation arbitration register whose size and position in the dual port memory 28 is not negotiable and hence may be statically located.

If the values proposed by the industrial controller 12 are not acceptable to the network card 18, then at process block 86, the network card 18 rewrites the default values from the nonvolatile memory 41 to the common area 66 and at process block 84, an indication is made to the controller 12 of the result of that evaluation via the negotiation arbitration register.

In the preferred embodiment, a value of one is written to the negotiation arbitration register in the common area 66 if the values proposed by the controller 12 are acceptable, but if they are not acceptable, then a value of zero is written to the negotiation arbitration register.

In either case, an interrupt is then issued by the network card 18 as indicated by interrupt symbol 88 to reply to the controller 12 which may read the negotiation arbitration register to determine whether its proposed values have been accepted.

At a much later time, the controller 12 may send an instruction as indicated by process block 90 to the card via the message areas requesting a change in the buffer values and offering values in the instruction data field. These instructions may be received as indicated by process block 92 and evaluated in a similar manner as the evaluation occurring at decision block 82 but as shown in decision block 94. If the values are acceptable, they are written to the common area 66 by the network card 18 as indicated by process block 96 and a reply is made in process block 98 via the negotiation arbitration register in a manner similar to that shown in process block 84, however, without the need for interrupts.

In this way, the benefit of default value is obtained while establishing a negotiation between the two devices of the controller 12 and the network card 18 such as allows for flexible application of the network card 18 to different controllers 12.

The above description has been that of a preferred embodiment of the present invention, it will occur to those that practice the art that many modifications may be made without departing from the spirit and scope of the invention. In order to apprise the public of the various embodiments that may fall within the scope of the invention, the following claims are made. 

We claim:
 1. An interface for a network card that is replaceably attached to an industrial controller to transmit messages sent from the industrial controller to a network and to receive messages from the network for the industrial controller, the interface comprising: a first and second buffer; a valid buffer register holding a value indicating the first or second buffer; a consumer access register holding a value indicating the first or second buffer, or when cleared neither of the first nor second buffers; an electronic computer executing a stored program to: (a) prior to reading one of the first and second buffers: (i) copy a value of the valid buffer register to the consumer access register; (ii) confirm that the value of the consumer access register equals the value of the valid buffer register; (b) upon confirmation, read a buffer indicated by the consumer access register; and (c) upon completion of the reading, clear the consumer access register.
 2. The interface of claim 1 wherein the electronic computer further copies for a second time a value of the valid buffer register to the consumer access register when the value of the consumer access register cannot be confirmed to equal the value of the valid buffer register.
 3. The interface of claim 1 wherein the valid buffer register, the consumer access register and the first and second buffers are designated portions of a dual port memory.
 4. The interface of claim 3 wherein the dual port memory is contained in the network card.
 5. The interface of claim 1 wherein the clearing of the consumer access resister writes a value of zero to the consumer access register.
 6. A interface for a network card that is replaceably attached to an industrial controller to transmit messages sent from the industrial controller to the network and to receive messages from the network for the industrial controller, the interface comprising: a first and second buffer; a valid buffer register holding a value indicating the first or second buffer; a consumer access register holding a value indicating the first or second buffer, or when cleared, neither of the first nor second buffers; an electronic computer executing a stored program to: (a) prior to a writing to one of the first and second buffers, read the consumer access register; (b) when the consumer access register indicates a reading of one of the first and second buffers: (i) write the value of the consumer access register to the valid buffer register (ii) write to a buffer that is not indicated by the consumer access register; (iii) write the value of the written buffer in the valid buffer register upon completion of writing; (c) when the consumer access register indicates neither of the first and second buffers, (i) read the valid buffer register; (ii) write to a buffer that is not indicated by the valid buffer register; and (iii) write a value of the written buffer in the valid buffer register upon completion of the writing.
 7. The interface of claim 6 wherein the valid buffer register, the consumer access register and the first and second buffers are designated portions of a dual port memory.
 8. The interface of claim 7 wherein the dual port memory is contained in the network Card.
 9. The interface for a network card of claim 2 wherein the electronic computer further executes the stored program to: (d) prior to reading one of the first and second buffers: (i) copying a value of the valid buffer register to the consumer access register; (ii) confirming that the value of the consumer access register equals the value of the valid buffer register; (e) reading a buffer indicated by the consumer access register; and (f) upon completion of the reading, clearing the consumer access register.
 10. A method of interfacing a network card to a host industrial controller, the interface communicating messages sent from the industrial controller to the network and receiving messages from the network for the industrial controller, the interface further including: a first and second buffer; a valid buffer register holding a value indicating the first or second buffer; a consumer access register holding a value indicating the first or second buffer, or when cleared neither of the first nor second buffers, and an electronic computer communicating with the first and second; the method comprising operating the electronic computer to perform the steps of (a) prior to reading one of the first and second buffers: (i) copy a value of the valid buffer register to the consumer access register; (ii) confirm that the value of the consumer access register equals the value of the valid buffer register; (b) read a buffer indicated by the consumer access register; and (c) upon completion of the reading, clear the consumer access register; (d) prior to a writing to one of the first and second buffers read the consumer access register; (e) when the consumer access register indicates one of the first and second buffers: (i) write the value of the consumer access register to the valid buffer register (ii) write to a buffer that is not indicated by the consumer access register; (iii) write the value of the written buffer in the valid buffer register; (f) when the consumer access register indicates neither of the first and second buffers, (i) read the valid buffer register; (ii) write to a buffer that is not indicated by the valid buffer register; and (iii) write a value of the written buffer in the valid buffer register.
 11. The method of claim 10 further including operating the electronic computer to perform the steps of: (d) prior to reading one of the first and second buffers: (i) copying a value of the valid buffer register to the consumer access register; (ii) confirming that the value of the consumer access register equals the value of the valid buffer register; (e) reading a buffer indicated by the consumer access register; and (f) upon completion of the reading, clearing the consumer access register. 